15.

Theories of Failure
Theory at a Glance (for IES, GATE, PSU)
1. Introduction
• Failure: Every material has certain strength, expressed in terms of stress or strain, beyond

which it fractures or fails to carry the load.

• Failure Criterion: A criterion used to hypothesize the failure.

• Failure Theory: A Theory behind a failure criterion.

Why Need Failure Theories?

• To design structural components and calculate margin of safety.

• To guide in materials development.

• To determine weak and strong directions.

Failure Mode
• Yielding: a process of global permanent plastic deformation. Change in the geometry of the

object.

• Low stiffness: excessive elastic deflection.

• Fracture: a process in which cracks grow to the extent that the component breaks apart.

• Buckling: the loss of stable equilibrium. Compressive loading can lead to bucking in

columns.

• Creep: a high-temperature effect. Load carrying capacity drops.

Failure Modes:
Excessive elastic Yielding Fracture
deformation
1. Stretch, twist, or • Plastic deformation at room • Sudden fracture of brittle
bending temperature materials
2. Buckling • Creep at elevated • Fatigue (progressive
temperatures fracture)
3. Vibration • Yield stress is the important • Stress rupture at elevated
design factor temperatures
• Ultimate stress is the
important design factor
2. Maximum Principal Stress Theory
(W. Rankin’s Theory- 1850) – Brittle Material
The maximum principal stress criterion:
Page 400 of 429
Chapter--15 Theo
ories of Fa
ailure S K Mondal’s
• Ra
ankin stated
d max principal stress theory
t as folllows- a matterial fails by
y fracturing
g when the
la
argest princiipal stress exceeds the ultimate
u strrength σu in a simple tension test. That
T is, at
th
he onset of frracture, |σ1| = σu OR |σ
σ3| = σu
• Crrack will sttart at the most highly
y stressed point
p in a brittle materrial when th
he largest
prrincipal streess at that pooint reachess σu
• Crriterion hass good experrimental verrification, even though it assumess ultimate strength is
sa
ame in comp
pression and
d tension

ure surface according

Failu g to maximu
um princip
pal stress th
heory

• Th
his theory of
o yielding has
h very pooor agreemen
nt with experiment. How
wever, the theory
t has
beeen used succcessfully forr brittle matterials.
• Used to descrribe fracture of brittle materials
m su
uch as cast iron
i
• Liimitations
o Doesn
n’t distinguissh between tension or co
ompression
o Doesn
n’t depend on
o orientatiion of princcipal planess so only ap
pplicable to
o isotropic
materrials
• Generalizatioon to 3-D stress case is easy:
e

3. Maximum She ear Stress

s or Stres
ss differe
ence theo
ory
(Guest’s or Tres
sca’s Theory-1868)- Ductilee Material
The Tressca Criterio
on:
• Allso known as the Maxim
mum Shear Stress
S criterrion.
• Yiielding will occur when the maximu
um shear sttress reaches that which
h caused yie
elding in a
simple tension
n test.
Page 401 of 429
C
Chapter-15 Theorie
es of Failure S K Mo
ondal’s
• Recall that yield
ding of a material
m occu
urred by slip
ppage betweeen planes oriented at 45° to
princcipal stressees. This shoould indicatee to you tha
at yielding of a material depends on the
maxiimum shear stress in the material rather
r than the um normal stress.
t maximu
If σ 1 > σ 2 > σ 3 Then
T σ1 − σ 3 = σ y

• Failu
ure by slip (yielding)
( occcurs when the
t maximu g stress, τ max exceeds th
um shearing he yield

stress τ f as deterrmined in a uniaxial ten

nsion test.

• This theory givess satisfactory

ry result for ductile ma
aterial.

Failur
re surface according
a t maximu
to um shear sttress theory
y

4 Strain Energy
4. E Th
heory (Ha
aigh’s Theory)
T
The theory associated
d with Haig
gh
T
This theory is
i based on the assump
ption that sttrains are re
ecoverable up
u to the ela
astic limit, and
a the
energy absorrbed by the material
m at failure
f up too this point is a single valued
v function indepen
ndent of
th
he stress system causin
ng it. The strrain energy per unit vollume causin
ng failure is equal to the
e strain
energy at thee elastic limiit in simple tension.

1 σ y2
U= ⎡σ 1 + σ 2 + σ 3 − 2μ (σ 1σ 2 + σ 2σ 3 + σ 3σ 1 ) ⎦ =
2 2 2
⎤
2E ⎣ 2E
σ 12 + σ 22 + σ 32 − 2μ (σ 1σ 2 + σ 2σ 3 + σ 3σ 1 ) = σ y2 For 3D-
3 stress

σ 12 + σ 22 − 2μσ
μ 1σ 2 = σ y2 For 2D-
2 stress

5 Shear Strain
5. S En
nergy Theeory (Disttortion En
nergy The
eory or M
Mises-Hen
nky
Theory
y or Von-M
Misses Theory)-Du uctile Maaterial
V
Von-Mises C
Criterion:
• Also known as th
he Maximum
m Energy of Distortion criterion
c
• Page
Based on a more complex vieew of the rolle of the402 ofncipal
prin 429 stresss differencess.
Chapter--15 Theo
ories of Fa
ailure S K Mondal’s
• In
n simple term
ms, the von Mises criterrion considerrs the diameeters of all tthree Mohr’ss circles as
coontributing to
t the characterization of
o yield onse
et in isotropiic materials.
• W
When the critterion is app
plied, its rela
ationship to the uniaxia
al tensile yield strength is:

• Foor a state off plane stress ( σ3 =0)

σ 12 − σ 1σ 2 + σ 22 = σ y2
• It is often con
nvenient to express
e this as an equivalent stress, σ e:
1 ⎡ 2 2 2⎤
1/2
σe = ⎢⎣(σ1 − σ2 ) + (σ2 − σ3 ) + (σ3 − σ1 ) ⎥⎦
2
1 ⎡ 2 2 2 2 2 2 ⎤ 1/2
or σe = ⎢⎣(σ x − σ y ) + (σ y − σz ) + (σ x − σz ) + 6(
6 τ xy + τ yz + τ zx )⎥⎦
2
• In
n formulatin
ng this failurre theory wee used generalized Hooke's law for an isotropicc material
soo the theory
y given is only appliccable to tho
ose materials but it ca
an be generalized to
an
nisotropic materials.
m
• Th
he von Misees theory is a little lesss conservativ
ve than the Tresca theoory but in most
m cases
th
here is little difference in
i their pred
dictions of fa
ailure. Mostt experimenttal results te
end to fall
on
n or between
n these two theories.
t
• It gives very good
g result in
i ductile material.
m

6. Maximum Prin
ncipal Strrain Theo
ory (St. Ve
enant The
eory)
According
g to this theeory, yieldin
ng will occurr when the maximum principal sttrain just ex
xceeds the
strain at the tensile yield point in either sim n or compreession. If ε1 and ε2 are maximum
mple tension
and minim
mum princip
pal strains correspondin
c ng to σ1 and σ2, in the lim
miting case

Page 403 of 429

C
Chapter-15 Theorie
es of Failure S K Mo
ondal’s

7 Mohr’s theory- Brittle

7. B Ma
aterial
M
Mohr’s Theo
ory
• Mohrr’s theory iss used to prredict the fracture
fr of a material having
h diffeerent properrties in
tensiion and comp
pression. Crriterion mak
kes use of Mo
ohr’s circle
• at τ depends on σ, or τ = f(σ). Note the
In Mohr’s circle, we note tha t vertical line PC reprresents
o planes with same σ but differing τ , which means
statees of stress on m the weeakest plane
e is the
one with
w um τ , pointt P.
maximu
• Pointts on the outer
o circle are the weeakest planes. On thesse planes th
he maximu
um and
minim
mum princip
pal stresses are sufficien
nt to decide whether or not failure w
will occur.
• Expeeriments aree done on a given mateerial to dete
ermine the states of strress that re
esult in
failurre. Each sta
ate defines a Mohr’s ciircle. If the
e data are obtained
o froom simple tension,
simple compression, and purre shear, the three resu
ulting circless are adequa
ate to constrruct an
enve
elope (AB & A’B’)
• Mohrr’s envelope thus represents the locu
us of all possible failuree states.

H
Higher shearr stresses arre to the lefft of origin, since most brittle mateerials have higher stren
ngth in
compression

8 Comparison
8.
A comparison
n among thee different failure
f theorries can be made
m by sup
perposing th
he yield surfa
faces as
shown in figu
ure

Page 404 of 429

Chapter--15 Theo
ories of Fa
ailure S K Mondal’s

Page 405 of 429

Chapter-15 Theories of Failure S K Mondal’s

OBJECTIVE QUESTIONS (GATE, IES, IAS)

Previous 20-Years GATE Questions

Maximum Shear stress or Stress Difference Theory

GATE-1. Match 4 correct pairs between list I and List II for the questions [GATE-1994]
List-I List-II
(a) Hooke's law 1. Planetary motion
(b) St. Venant's law 2. Conservation Energy
(c) Kepler's laws 3. Elasticity
(d) Tresca's criterion 4. Plasticity
(e) Coulomb's laws 5. Fracture
(f) Griffith's law 6. Inertia
GATE-1. Ans. (a) - 3, (c) -1, (d) -5, (e) -2
St. Venant's law: Maximum principal strain theory

GATE-2. Which theory of failure will you use for aluminium components under steady
loading? [GATE-1999]
(a) Principal stress theory (b) Principal strain theory
(c) Strain energy theory (d) Maximum shear stress theory
GATE-2. Ans. (d) Aluminium is a ductile material so use maximum shear stress theory

Shear Strain Energy Theory (Distortion energy theory)

GATE-3. According to Von-Mises' distortion energy theory, the distortion energy under
three dimensional stress state is represented by [GATE-2006]

GATE-3. Ans. (c)

Vs =
1
12G
{
(σ 1 − σ 2 ) + (σ 2 − σ 3 ) + (σ 3 − σ 1 )
2 2 2
} Where E = 2G(1 + μ ) simplify and get result.

GATE-4. A small element at the critical section of a component is in a bi-axial state of

stress with the two principal stresses being 360 MPa and 140 MPa. The
maximum working stress according to Distortion Energy Theory is:
[GATE-1997]
(a) 220 MPa (b) 110 MPa (c) 314 MPa (d) 330 MPa
GATE-4. Ans. (c) According to distortion energy theory if maximum stress (σt) then
or σ t2 = σ 12 + σ 22 − σ 1σ 2
or σ t2 = 3602 + 1402 − 360 × 140
or σ t = 314 MPa
Page 406 of 429
Chapter--15 Theo
ories of Fa
ailure S K Mondal’s

Pre
evious
s 20-Y
Years IES
I Qu
uestio
ons

Maxim
mum Principa
P al Stres
ss The
eory
IES-1. Match Liist-I (Theor ry of Failure) with Liist-II (Pred
dicted Ratio o of Shear Stress to
Direct Stress
S at Yield
Y Condition for Steel
S Speciimen) and select the e correct
answer using
u the code given below
b the Lists:
L [IIES-2006]
List-I List-II
A. Maxim mum shear sttress theoryy 1. 1·0
B. Maxim mum distortion energy th heory 2. 0·577
C. Maxim mum principaal stress theeory 3. 0·62
D. Maxim mum principaal strain theeory 4. 0·50
Codes: A B C D A B C D
(a) 1 2 4 3 (b
b) 4 3 1 2
(c) 1 3 4 2 (d
d) 4 2 1 3
ns. (d)
IES-1. An

IES-2. From a tension

t tesst, the yieldd strength of steel is found to be 200 N/mm m2. Using
a factor of safety of 2 and app plying max ximum prin ncipal stresss theory ofo failure,
the perm missible stress in the steel
s shaft subjected to
t torque w will be: [IIES-2000]
(a) 50 N/mmm2 (b) 57.7 N/mm
N 2 (c) 86.6. N/mm2 (d) 100 N/mm2
ns. (d) For pure
IES-2. An p shear τ = ±σ x

IES-3. A circular solid shhaft is sub bjected to a bendingg moment of 400 kN

Nm and a
twisting moment of o 300 kNm m. On the basis of th
he maximu
um princip
pal stress
theory, the
t direct stress is σ and acc cording to
o the maximum shea ar stress
theory, the
t shear sttress is τ . The
T σ τ is:
ratio σ/ [IIES-2000]
1 3 9 11
(a ) (b) (c) (d)
5 9 5 6
ns. (c) σ =
IES-3. An
16
π d3(M + M2 + T 2 ) and τ =
16
π d3 ( M2 + T 2 )
σ M + M2 + T 2 4 + 42 + 32 9
Therefore = = =
τ M2 + T 2 42 + 32 5

IES-4. A transm mission sha aft subjecte

ed to bendiing loads must
m be designed on the basis
of [IIES-1996]
(a) Maximmum normall stress theory
(b) Maximmum shear stress
s theory
y
(c) Maximmum normal stress and maximum
m sh
hear stress theories
t
(d) Fatigu
ue strength
ns. (a)
IES-4. An

IES-5. Design ofo shafts ma als is based on

ade of britttle materia [IIES-1993]
(a) Guest''s theory (b
b) Rankine’s theory (cc) St. Venantt's theory (d)) Von Mises theory
ns. (b) Ran
IES-5. An nkine's theorry or maxim
mum principple stress th
heory is mosst commonly y used for
brittle ma
aterials.

Maxim
mum Shear
S s
stress o Stress Diffference
or e Theory
IES-6. Which onne of the fo
ollowing fig
gures repre
esents the maximum shear stress theory
or Tresca
a criterion
n? [IIES-1999]

Page 407 of 429

Chapter-15 Theories of Failure S K Mondal’s
IES-6. Ans. (b)

IES-7. According to the maximum shear stress theory of failure, permissible twisting
moment in a circular shaft is 'T'. The permissible twisting moment will the
same shaft as per the maximum principal stress theory of failure will be:
[IES-1998: ISRO-2008]
(a) T/2 (b) T (c) 2T (d) 2T
16T σ yt
IES-7. Ans. (d) Given τ = = principal stresses for only this shear stress are
π d3 2
σ 1,2 = τ 2 = ±τ maximum principal stress theory of failure gives
16 ( 2T )
max[σ 1,σ 2 ] = σ yt =
π d3
IES-8. Permissible bending moment in a circular shaft under pure bending is M
according to maximum principal stress theory of failure. According to
maximum shear stress theory of failure, the permissible bending moment in
the same shaft is: [IES-1995]
(a) 1/2 M (b) M (c) 2M (d) 2M

IES-8. Ans. (b) σ =

16
π d3
(
M + M2 + T 2 )16
(
and τ = 3 M2 + T 2 put T = 0
πd
)
⎛ 32M ⎞
32M 16M′ σ yt ⎜⎝ π d3 ⎟⎠ 16M
or σ yt = and τ = = = = ThereforeM′ = M
π d3 π d3 2 2 π d3

IES-9. A rod having cross-sectional area 100 x 10- 6 m2 is subjected to a tensile load.
Based on the Tresca failure criterion, if the uniaxial yield stress of the material
is 200 MPa, the failure load is: [IES-2001]
(a) 10 kN (b) 20 kN (c) 100 kN (d) 200 kN
IES-9. Ans. (b) Tresca failure criterion is maximum shear stress theory.
P sin 2θ P σ yt
We know that,τ = or τ max = = or P = σ yt × A
A 2 2A 2

IES-10. A cold roller steel shaft is designed on the basis of maximum shear stress
theory. The principal stresses induced at its critical section are 60 MPa and - 60
MPa respectively. If the yield stress for the shaft material is 360 MPa, the
factor of safety of the design is: [IES-2002]
(a) 2 (b) 3 (c) 4 (d) 6
IES-10. Ans. (b)

IES-11. A shaft is subjected to a maximum bending stress of 80 N/mm2 and maximum

shearing stress equal to 30 N/mm2 at a particular section. If the yield point in
tension of the material is 280 N/mm2, and the maximum shear stress theory of
failure is used, then the factor of safety obtained will be: [IES-1994]
(a) 2.5 (b) 2.8 (c) 3.0 (d) 3.5
2
⎛ 80 − 0 ⎞
⎟ + 30 = 50 N/mm
2 2
IES-11. Ans. (b) Maximum shear stress = ⎜
⎝ 2 ⎠
σy 280
According to maximum shear stress theory, τ = ; ∴ F .S . = = 2.8
2 2 × 50

IES-12. For a two-dimensional state stress ( σ 1 > σ 2 , σ 1 > 0, σ 2 < 0 ) the designed values
are most conservative if which one of the following failure theories were used?
[IES-1998]
(a) Maximum principal strain theory (b) Maximum distortion energy theory
(c) Maximum shear stress theory (d) Maximum principal stress theory
Page 408 of 429
IES-12. Ans. (c)
Chapter-15 Theories of Failure S K Mondal’s

Graphical comparison of different failure theories

Above diagram shows that σ 1 > 0, σ 2 < 0 will occur at 4th quadrant and most
conservative design will be maximum shear stress theory.

Shear Strain Energy Theory (Distortion energy theory)

IES-13. Who postulated the maximum distortion energy theory? [IES-2008]
(a) Tresca (b) Rankine (c) St. Venant (d) Mises-Henky
IES-13. Ans. (d)

IES-14. Who postulated the maximum distortion energy theory? [IES-2008]

(a) Tresca (b) Rankine (c) St. Venant (d) Mises-Henky
IES-14. Ans. (d)
Maximum shear stress theory → Tresca
Maximum principal stress theory → Rankine
Maximum principal strain theory → St. Venant
Maximum shear strain energy theory → Mises – Henky

IES-15. The maximum distortion energy theory of failure is suitable to predict the
failure of which one of the following types of materials? [IES-2004]
(a) Brittle materials (b) Ductile materials (c) Plastics (d) Composite materials
IES-15. Ans. (b)
IES-16. If σy is the yield strength of a particular material, then the distortion energy
theory is expressed as [IES-1994]
(σ 1 − σ 2 ) + ( σ 2 − σ 3 ) + (σ 3 − σ 1 )
2 2 2
(a) = 2σ y2
(b) (σ 2
1 − σ 22 + σ 32 ) − 2 μ (σ 1σ 2 + σ 2σ 3 + σ 3σ 1 ) = σ y2
(σ 1 − σ 2 ) + (σ 2 − σ 3 ) + (σ 3 − σ 1 ) = 3σ y2
2 2 2
(c)

(d) (1 − 2 μ )(σ 1 + σ 2 + σ 3 ) = 2 (1 + μ ) σ y
2 2

IES-16. Ans. (a)

IES-17. If a shaft made from ductile material is subjected to combined bending and
twisting moments, calculations based on which one of the following failure
theories would give the most conservative value? [IES-1996]
(a) Maximum principal stress theory (b) Maximum shear stress theory.
(d Maximum strain energy theory (d) Maximum distortion energy theory.
IES-17. Ans. (b)

Page 409 of 429

Chapter-15 Theories of Failure S K Mondal’s

Maximum Principal Strain Theory

IES-18. Match List-I (Failure theories) with List-II (Figures representing boundaries of
these theories) and select the correct answer using the codes given below the
Lists: [IES-1997]
List-I List-II
A. Maximum principal stress
theory

B. Maximum shear stress theory

C. Maximum octahedral stress

theory

D. Maximum shear strain

energy theory

Code: A B C D A B C D
(a) 2 1 3 4 (b) 2 4 3 1
(c) 4 2 3 1 (d) 2 4 1 3
IES-18. Ans. (d)

Previous 20-Years IAS Questions

Maximum Principal Stress Theory

IAS-1. For σ1 ≠ σ 2 and σ3 = 0, what is the physical boundary for Rankine failure
theory? [IAS-2004]
(a) A rectangle (b) An ellipse (c) A square (d) A parabola

Page 410 of 429

Chapter-15 Theories of Failure S K Mondal’s
IAS-1. Ans. (c) Rankine failure theory or
Maximum principle stress theory.

Shear Strain Energy Theory (Distortion energy theory)

IAS-2. Consider the following statements: [IAS-2007]
1. Experiments have shown that the distortion-energy theory gives an
accurate prediction about failure of a ductile component than any other
theory of failure.
2. According to the distortion-energy theory, the yield strength in shear is less
than the yield strength in tension.
Which of the statements given above is/are correct?
(a) 1 only (b) 2 only (c) Both 1 and 2 (d) Neither 1 nor 2
σy
IAS-2. Ans. (c) τy = = 0.577σ y
3

IAS-3. Consider the following statements: [IAS-2003]

1. Distortion-energy theory is in better agreement for predicting the failure of
ductile materials.
2. Maximum normal stress theory gives good prediction for the failure of
brittle materials.
3. Module of elasticity in tension and compression are assumed to be different
stress analysis of curved beams.
Which of these statements is/are correct?
(a) 1, 2 and 3 (b) 1 and 2 (c) 3 only (d) 1 and 3
IAS-3. Ans. (b)

IAS-4. Which one of the following graphs represents Mises yield criterion? [IAS-
1996]

IAS-4. Ans. (d)

Maximum Principal Strain Theory

IAS-5. Given that the principal stresses σ1 > σ 2 > σ 3 and σe is the elastic limit stress in
simple tension; which one of the following must be satisfied such that the
elastic failure does not occur in accordance with the maximum principal strain
theory? [IAS-2004]
σe ⎛σ σ σ ⎞ σe⎛σ σ σ ⎞
(a) <⎜ 1 −μ 2 −μ 3 ⎟ (b) >⎜ 1 −μ 2 −μ 3 ⎟
E ⎝E E E⎠ E ⎝E E E⎠
Page 411 of 429
Chapter-15 Theories of Failure S K Mondal’s
σe⎛σ σ σ ⎞ σe⎛σ σ σ ⎞
(c) >⎜ 1 +μ 2 +μ 3 ⎟ (d) <⎜ 1 +μ 2 −μ 3 ⎟
E ⎝E E E⎠ E ⎝E E E⎠
IAS-5. Ans. (b) Strain at yield point>principal strain
σe σ1 σ2 σ3
> −μ −μ
E E E E

Page 412 of 429

Chapter-15 Theories of Failure S K Mondal’s

Previous Conventional Questions with Answers

Conventional Question ESE-2010
Q. The stress state at a point in a body is plane with
σ 1 = 60N / mm 2 & σ 2 = −36 N / mm 2
If the allowable stress for the material in simple tension or compression is
100 N/mm2 calculate the value of factor of safety with each of the following
criteria for failure
(i) Max Stress Criteria
(ii) Max Shear Stress Criteria
(iii) Max strain criteria
(iv) Max Distortion energy criteria [10 Marks]

Ans. The stress at a point in a body is plane

σ1 = 60 N / mm2 σ2 = −36 N / mm2
Allowable stress for the material in simple tension or compression is 100 N/mm2
Find out factor of safety for
(i) Maximum stress Criteria : - In this failure point occurs when max principal stress
reaches the limiting strength of material.
Therefore. Let F.S factor of safety
σ ( allowable )
σ1 =
F.S
100 N / mm2
F.S = = 1.67 Ans.
60 N / mm2
(ii) Maximum Shear stress criteria : - According to this failure point occurs at a point in a
member when maximum shear stress reaches to shear at yield point
σyt
γ max = σyt = 100 N / mm2
2 F.S
σ1 − σ2 60 + 36 96
γ max = = = = 48 N / mm2
2 2 2
100
48 =
2 × F.S
100 100
F.S = = = 1.042
2 × 48 96
F.S = 1.042 Ans.
(iii) Maximum Strain Criteria ! – In this failure point occurs at a point in a member when
maximum strain in a bi – axial stress system reaches the limiting value of strain (i.e
strain at yield point)
2
⎛σ ⎞
σ 12
+ σ 22
− 2μσ 1σ 2 = ⎜ allowable ⎟
⎝ FOS ⎠
FOS = 1.27
( μ = 0.3assume)
(iv) Maximum Distortion energy criteria ! – In this failure point occurs at a point in a
member when distortion strain energy per unit volume in a bi – axial system reaches the
limiting distortion strain energy at the of yield

Page 413 of 429

Chapter-15 Theories of Failure S K Mondal’s
2
⎛σ ⎞
σ12 + σ22 − σ1 × σ2 = ⎜ yt ⎟
⎝ F.S ⎠
2
⎛ 100 ⎞
60 + ( 36 ) − ×60 × −36 = ⎜
2 2
⎟
⎝ F.S ⎠
F.S = 1.19

Conventional Question ESE-2006

Question: A mild steel shaft of 50 mm diameter is subjected to a beading moment of 1.5
kNm and torque T. If the yield point of steel in tension is 210 MPa, find the
maximum value of the torque without causing yielding of the shaft material
according to
(i) Maximum principal stress theory
(ii) Maximum shear stress theory.
32M
Answer: We know that, Maximum bending stress (σb ) =
πd 3
16T
and Maximum shear stress (τ ) =
πd 3
Principal stresses are given by:
2
σ ⎛σ ⎞ 16 ⎡ 2⎤
σ1,2 = b ± ⎜⎜ b ⎟⎟⎟ + τ 2 = 2
⎢M ± M + T ⎥⎦
2 ⎜
⎝2⎠ πd 3 ⎣
(i ) According to Maximum principal stress theory
Maximum principal stress=Maximum stress at elastic limit (σ y )
16 ⎡M + M 2 + T 2 ⎤ = 210 ×106
or ⎢⎣ ⎥⎦
πd 3
16 ⎡1500 + 15002 + T 2 ⎤ = 210 ×106
or 3 ⎢⎣ ⎥⎦
π (0.050)
or T = 3332 Nm = 3.332 kNm
(ii ) According to Maximum shear stress theory
σ1 − σ 2 σ y
τmax = =
2 2
or , σ1 − σ 2 = σ y
16
or , 2× 3
M 2 + T 2 = 210 ×106
πd
or , T = 2096 N m = 2.096 kNm

Conventional Question ESE-2005

Question: Illustrate the graphical comparison of following theories of failures for two-
dimensional stress system:
(i) Maximum normal stress theory
(ii) Maximum shear stress theory
(iii) Distortion energy theory Page 414 of 429
Answer:
Chapter--15 Theo
ories of Fa
ailure S K Mondal’s

Conventtional Que
estion ESE
E-2004
Question
n: State th
he Von- Miises's theor ry. Also givve the natur rally expreession.
Answer: Accordinng to this theory
t yielding would occur
o when total distorrtion energy
y absorbed
per unitt volume duue to applied d loads exceeeds the distortion enerrgy absorbed
d per unit
volume at the tensiile yield poin
nt. The failu
ure criterion is
2 2 2
(σ1 − σ 2 ) + (σ 2 − σ 3 ) + (σ 3 − σ1) = 2σ 2y
[sym
mbols has usual
u meaning]

Conventtional Que
estion ESE
E-2002
Question
n: Derive an expresssion for the distortiion energy
y per unit volume fo or a body
subjectted to a uniform
u ress state, given by the σ 1 and
str d σ 2 with the
t third
pal stress σ3 being ze
princip ero.
Answer: Accordinng to this theory
t yielding would occur
o when total distorrtion energy
y absorbed
per unitt volume duue to appliedd loads exceeeds the distortion enerrgy absorbedd per unit
volume at the tensiile yield point. Total strrain energy ET and straain energy for
f volume
change EV can be giiven as

Substitu
uting strains in terms of
o stresses th
he distortion
n energy can
n be given ass

At the tensile
t yield point, σ1 = σy , σ2 = σ3 = 0 which gives

The faillure criterion

n is thus obttained by eq
quating Ed and Edy , whiich gives

In a 2-D
D situation iff σ3 = 0, the criterion red
duces to

Conventtional Que
estion GAT
TE-1996
Question
n: A cube of 5mm sid
de is loaded as shownn in figure below.
(i) Determine the
t princip s σ1 ,σ2 ,σ3 .
pal stresses
(ii) Will the cub
W be yield if the yield strength
s off the mater
rial is 70 MPa?
M Use
Von-Mises th heory. Page 415 of 429
Answer: he material σet = 70 MPa
Yield sttrength of th a = 70 MN/m
m2 or 70 N/m
mm2.
Chapter-15 Theories of Failure S K Mondal’s

(i) Principal stress σ1, σ2 , σ3 :

2000 1000
σx = = 80 N/mm2 ; σy = = 40 N/mm2
5×5 5×5
500 800
σz = = 20 N/mm2 ; τ xy = = 32 N/mm2
5×5 5×5
σ x + σy ⎛ σ x − σ y ⎞⎟ 80 + 40
2
⎛ 80 − 40 ⎞⎟
± ⎜⎜⎜ ⎜⎜⎜
2
⎟ + τ xy ⎟⎟ + (32)
2
σ= ⎟ = ±
2 ⎝⎜ 2 ⎠⎟ 2 ⎝ 2 ⎠
2 2
= 60 ± (20) + (32) = 97.74, 22.26
∴ σ1 = 97.74N/mm2 , or 97.74 MPa
and σ2 = 22.96N/mm2 or 22.96 MPa
σ3 = σz = 20N/mm2 or 22 MPa
(ii) Will the cube yieldor not?
According to Von-Mises yield criteria, yielding will occur if
2 2 2
(σ1 − σ2 ) + (σ2 − σ3 ) + ( σ3 − σ1) ≥ 2σyt2
2 2 2
Now (σ1 − σ2 ) + (σ2 − σ3 ) + ( σ3 − σ1)
2 2 2
= (97.74 − 22.96) + (22.96 − 20) + (20 − 97.74)
= 11745.8 −− − (i )
2
and, 2σyt2 = 2 ×(70) = 9800 −− − (ii )
Since 11745.8 > 9800 so yielding will occur.
Conventional Question GATE-1995
Question: A thin-walled circular tube of wall thickness t and mean radius r is subjected
to an axial load P and torque T in a combined tension-torsion experiment.
(i) Determine the state of stress existing in the tube in terms of P and T.
(ii) Using Von-Mises - Henky failure criteria show that failure takes place
σ 2 + 3τ 2 = σ0 , where σ0 is the yield stress in uniaxial tension,
when
σ and τ are respectively the axial and torsional stresses in the tube.

Answer: Mean radius of the tube = r,

Wall thickness of the tube = t,
Axial load = P, and
Page 416 of 429
Torque = T.
(i) The state of stress in the tube:
Chapter-15 Theories of Failure S K Mondal’s
P
Due to axial load, the axial stress in the tube σ x =
2πrt
Due to torque, shear stress,
Tr Tr T
τ xy = = =
J 2πr t 2πr 3 t
3

π
J=
2
{ 4
}
(r + t ) − r 4 = 2πr 3t -neglecting t 2 higher power of t.
P T
∴ The state of stress in the tube is, σ x = , σy = 0, τ xy =
2πrt 2πr 3 t
(ii) Von Mises-Henky failure in tension for 2-dimensional stress is
σ02 = σ12 + σ22 − σ1σ2

σx + σy ⎛ σ − σ y ⎞⎟2
σ1 = + ⎜⎜⎜ x ⎟ + τ xy
2

2 ⎜⎝ 2 ⎠⎟⎟
2
σ x + σy ⎛ σ x − σ y ⎞⎟
σ2 = − ⎜⎜⎜ ⎟⎟ + τ xy
2

2 ⎜⎝ 2 ⎠ ⎟

σx σ x2 2
In this case, σ1 = + + τ xy , and
2 4
σx σ2
σ2 =
2
2
− x + τ xy
4
(∵ σy = 0)
2 2 2
⎡σ σ x2 ⎤ ⎡σ 2 ⎤ ⎡ 2 ⎤⎡ 2 ⎤
∴ σ = ⎢⎢ x +
2 2 ⎥
+ τ xy + ⎢ x − σx + τ 2 ⎥ − ⎢ σx + σx + τ 2 ⎥ ⎢ σx − σx + τ 2 ⎥
0 ⎥ ⎢2 xy ⎥ ⎢2 xy ⎥ ⎢ xy ⎥
⎢⎣ 2 4 ⎥⎦ ⎢⎣ 4 ⎥⎦ ⎢⎣ 4 ⎥⎦ ⎢⎣ 2 4 ⎥⎦
⎡ σ2 σ2 σ σ2 ⎤ ⎡σ2 σ2 2 ⎤
= ⎢⎢ x + x + τ xy2
+ 2. x . x + τ xy 2 ⎥
+ ⎢ x + x + τ 2 + 2. σ x . σ x + τ 2 ⎥
⎥ ⎢4 xy xy ⎥
⎢⎣ 4 4 2 4 ⎥⎦ ⎢⎣ 4 2 4 ⎥⎦
⎡ σ2 σ2 ⎤
− ⎢ x − x − τ xy 2 ⎥
⎢4 4 ⎥
⎣ ⎦
= σ x2 + 3τ xy
2

σ0 = σ x2 + 3τ xy
2

Conventional Question GATE-1994

Question: Find the maximum principal stress developed in a cylindrical shaft. 8 cm in
diameter and subjected to a bending moment of 2.5 kNm and a twisting
moment of 4.2 kNm. If the yield stress of the shaft material is 300 MPa.
Determine the factor of safety of the shaft according to the maximum
shearing stress theory of failure.
Answer: Given: d = 8 cm = 0.08 m; M = 2.5 kNm = 2500 Nm; T = 4.2 kNm = 4200 Nm
σyield (σyt ) = 300 MPa = 300 MN/m2
2 2
Equivalent torque, Te = M 2 + T 2 = (2.5) + (4.2) = 4.888 kNm
Maximum shear stress developed in the shaft,
16T 16 × 4.888 ×103
τmax = 3
= 3
×10−6 MN/m2 = 48.62MN/m2
πd π ×(0.08)
300
Permissible shear stress = = 150MN/m2
2
150 Page 417 of 429
∴ Factor of safety = = 3.085
48.62
16. Rive
eted and Weld
ded Joint
J

Th
heory at
a a Glance
G e (for IES,
I G
GATE, PSU)

Page 420 of 429

Chapter--16 Riveted
d and Welde
ed Joint S K Mondal’s

Page 421 of 429

Chapter-16 Riveted and Welded Joint S K Mondal’s

OBJECTIVE QUESTIONS (GATE, IES, IAS)

Previous 20-Years GATE Questions

Failure of riveted joint

GATE-1. Bolts in the flanged end of pressure vessel are usually pre-tensioned Indicate
which of the following statements is NOT TRUE? [GATE-1999]
(a) Pre-tensioning helps to seal the pressure vessel
(b) Pre-tensioning increases the fatigue life of the bolts
(c) Pre-tensioning reduces the maximum tensile stress in the bolts
(d) Pre-tensioning helps to reduce the effect of pressure pulsations in the pressure vessel
GATE-1. Ans. (c)

Statement for Linked Answers and Questions Q2 and Q3

A steel bar of 10 × 50 mm is cantilevered with two M 12 bolts (P and Q) to support a static
load of 4 kN as shown in the figure.

GATE-2. The primary and secondary shear loads on bolt P, respectively, are:
[GATE-2008]
(A) 2 kN, 20 kN (B) 20 kN, 2kN (C) 20kN,0kN (D) 0kN, 20 kN
4 kN
GATE-2. Ans. (a) Primary (Direct) Shear load = = 2k N
2

GATE-3. The resultant stress on bolt P is closest to [GATE-2008]

(A) 132 MPa (B) 159 MPa (C) 178 MPa (D) 195 MPa
GATE-3. Ans. (b)

GATE-4. A bolted joint is shown below. The maximum shear stress, in MPa, in the bolts
at A and B, respectively are: [GATE-2007]

Page 422 of 429

Chapter--16 Riveted
d and Welde
ed Joint S K Mondal’s

(a) 242.6, 42.5 (b) 42

25.5, 242.6 (c) 42.5, 42.5 42.6, 242.6
(d) 24
GATE-4. Ans. (a)

GATE-5. A bracke et (shown in

i figure) is
i rigidly mounted
m on
n wall usinng four rive
ets. Each
rivet is 6 mm in dia
ameter and
d has an efffective leng
gth of 12 m
mm. [GA
ATE-2010]

Direct sh
hear stress (in MPa) in the mostt heavily lo
oaded rivet is:
(a) 4.4 (b) 8.8
8 (c) 17.6 (d
d) 35.2
GATE-5. Ans. (b)
1000 F 250
F= = 250 N and z= = = 8.8MPa
4 A π (6) 2
4

Efficiency of
o a rive
eted jo
oint
GATE-6. If the raatio of the diameter
d o rivet holle to the piitch of rive
of ets is 0.25, then the
tearing efficiency
e o the joint is:
of [GAATE-1996]
(a) 0.50 (b) 0.7
75 (c) 0.2
25 (d) 0.8
87
GATE-6. Ans. (b)

Page 423 of 429

Chapter-16 Riveted and Welded Joint S K Mondal’s

GATE-7. A manufacturer of rivets claims that the failure load in shear of his product is
500 ± 25 N. This specification implies that [GATE-1992]
(a) No rivet is weaker than 475 N and stronger than 525 N
(b) The standard deviation of strength of random sample of rivets is 25 N
(c) There is an equal probability of failure strength to be either 475 Nor 525 N
(d) There is approximately two-to-one chance that the strength of a rivet lies between
475 N to 525 N
GATE-7. Ans. (a)

Previous 20-Years IES Questions

Failure of riveted joint

IES-1. An eccentrically loaded
riveted joint is shown with 4
rivets at P, Q, R and S.
Which of the rivets are the
most loaded?
(a) P and Q
(b) Q and R
(c) Rand S
(d) Sand P

[IES-2002]
IES-1. Ans. (b)

IES-2. A riveted joint has been designed to

support an eccentric load P. The load
generates value of F1 equal to 4 kN and F2
equal to 3 kN. The cross-sectional area of
each rivet is 500 mm2. Consider the
following statements:
1. The stress in the rivet is 10 N / mm2
2. The value of eccentricity L is 100 mm
3. The value of load P is 6 kN
4. The resultant force in each rivet is 6 kN
Which of these statements are correct?
(a) 1 and 2 (b) 2 and 3
(c) 3 and 4 (d) 1 and 3 [IES-2003]
IES-2. Ans. (d)

Page 424 of 429

Chapter-16 Riveted and Welded Joint S K Mondal’s
P = 2F2 = 2 x 3 = 6 kN
and P.L = F1l + F1l = 2 F1l
or 6 L = 2 × 4l = 8l
L 8
or =
l 6

Resultant force on rivet,

R = F12 +F22 +2F1F2 cosθ

( 4 ) + ( 3)
2 2
= + 2 × 4 × 3cos θ
= 5 kN

∴ Shear stress on rivet,

R 5×103
τ= = =10 N/mm 2
Area 500

IES-3. If permissible stress in

plates of joint through a
pin as shown in the
given figure is 200 MPa,
then the width w will be
(a) 15 mm
(b) 18 mm
(c) 20 mm
(d) 25 mm

[IES-1999]
IES-3. Ans. (a) (w – 10) × 2 × 10-6 × 200 × 106 = 2000 N; or w = 15 mm.

IES-4. For the bracket bolted as

shown in the figure, the bolts
will develop
(a) Primary tensile stresses and
secondary shear stresses
(b) Primary shear stresses and
secondary shear stresses
(c) Primary shear stresses and
secondary tensile stresses
(d) Primary tensile stresses and
secondary compressive
stresses
[IES-2000]
IES-4. Ans. (a)
IES-5. Assertion (A): In pre-loaded bolted joints, there is a tendency for failure to
occur in the gross plate section rather than through holes. [IES-2000]
Reason (R): The effect of pre-loading is to create sufficient friction between the
assembled parts so that no slippage occurs.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is NOT the correct explanation of A
Page 425 of 429
(c) A is true but R is false
(d) A is false but R is true
Chapter-16 Riveted and Welded Joint S K Mondal’s
IES-5. Ans. (a)

IES-6. Two rigid plates are clamped by means of bolt and nut with an initial force N.
After tightening, a separating force P (P < N) is applied to the lower plate,
which in turn acts on nut. The tension in the bolt after this is: [IES-1996]
(a) (N + P) (b) (N – P) (c) P (d) N
IES-6. Ans. (a)

Efficiency of a riveted joint

IES-7. Which one of the following structural joints with 10 rivets and same size of
plate and material will be the most efficient? [IES-1994]

IES-7. Ans. (b)

IES-8. The most efficient riveted joint possible is one which would be as strong in
tension, shear and bearing as the original plates to be joined. But this can
never be achieved because: [IES-1993]
(a) Rivets cannot be made with the same material
(b) Rivets are weak in compression
(c) There should be at least one hole in the plate reducing its strength
(d) Clearance is present between the plate and the rivet
IES-8. Ans. (c) Riveted joint can't be as strong as original plates, because there should be at least
one hole in the plate reducing its strength.

Advantages and disadvantages of welded joints

IES-9. Assertion (A): In a boiler shell with riveted construction, the longitudinal scam
is, jointed by butt joint. [IES-2001]
Reason (R): A butt joint is stronger than a lap joint in a riveted construction.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is NOT the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-9. Ans. (c)

Page 426 of 429

Chapter-16 Riveted and Welded Joint S K Mondal’s

Previous 20-Years IAS Questions

Failure of riveted joint

IAS-1. Two identical planks of
wood are connected by
bolts at a pitch distance
of 20 cm. The beam is
subjected to a bending
moment of 12 kNm, the
shear force in the bolts
will be:
(a) Zero (b) 0.1 kN
(c) 0.2 kN (d) 4 kN
[IAS-2001]
IAS-1. Ans. (a)

IAS-2. Match List-I with List-II and select the correct answer using the code given
below the Lists: [IAS-2007]
List-I List-II
(Stress Induced) (Situation/ Location)
A. Membrane stress 1. Neutral axis of beam
B. Torsional shear stress 2. Closed coil helical spring under axial load
C. Double shear stress 3. Cylindrical shell subject to fluid pressure
D. Maximum shear stress 4. Rivets of double strap butt joint
Code: A B C D A B C D
(a) 3 1 4 2 (b) 4 2 3 1
(c) 3 2 4 1 (d) 4 1 3 2
IAS-2. Ans. (c)

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Chapter-16 Riveted and Welded Joint S K Mondal’s

Previous Conventional Questions with Answers

Conventional Question GATE-1994
Question: The longitudinal joint of a thin cylindrical pressure vessel, 6 m internal
diameter and 16 mm plate thickness, is double riveted lap point with no
staggering between the rows. The rivets are of 20 mm nominal (diameter with
a pitch of 72 mm. What is the efficiency of the joint and what would be the
safe pressure inside the vessel? Allowable stresses for the plate and rivet
materials are; 145 MN/m2 in shear and 230 MN/m2 in bearing. Take rivet hole
diameter as 1.5 mm more than the rivet diameter.
Answer: Given: Diameter of rivet = 20 mm
Diameter of hole = 20 + 1.5 = 21.5 mm
Diameter the pressure vessel, d = 6 m
Thickness of the plate, t = 16 mm
Type of the joint: Double riveted lap joint
Allowable stresses:
σ 1 = 145 MN / m2 ; τ = 120 MN / m2 ; σ c = 230 MN / m2
⎡ 72 − ( 2 × 21.5 ) ⎤ 16
Strength of plate in tearing/pitch, Rt = ⎢ ⎥× × 145
⎣⎢ 1000 ⎦⎥ 1000
= 0.06728 MN
2
π
⎛ 20 ⎞
Strength of rivert in tearing/pitch,Rs = 2 × ×⎜ × 120
4 ⎝ 1000 ⎟⎠
= 0.0754 MN
⎛ 20 16 ⎞
Strength of plate in crushing/pitch,Rs = 2 × ⎜ × ⎟ × 230
⎝ 1000 1000 ⎠
= 0.1472 MN

From the above three modes of failure it can be seen that the weakest element is the
plate as it will have tear failure at 0.06728 MN/pitch load itself.
Stresses acting on the plate for an inside pressure of pN/m2 is shown in figure.
pd p×6
Hoop stress = = = 187.5 p
2t 2 × ( 0.016 )
pd p×6
Longitudinal stress = = = 93.75 p
4t 4 × ( 0.016 )
pd
Maximum principal stress acting on the plate =
2t
only ( i, e.187.5 p ) as there is no shear stress.
0.06728
or 187.5 p ≤ ≤ 145
⎡ 72 − ( 2 × 21.5 ) ⎤
( 0.016 ) × ⎢ 1000 ⎥
⎣ ⎦
or p ≤ 0.7733 MN / m2 or 0.7733 MPa
Page 428 of 429
Rt 0.06728
η jo int = = = 0.4028 = 40.28%
p.t.σ t ( 0.072 ) × ( 0.016 ) × 145
Chapter-16 Riveted and Welded Joint S K Mondal’s

Conventional Question GATE-1995

Question: Determine the shaft diameter and bolt size for a marine flange-coupling
transmitting 3.75 MW at 150 r.p.m. The allowable shear stress in the shaft and
bolts may be taken as 50 MPa. The number of bolts may be taken as 10 and
bolt pitch circle diameter as 1.6 times the shaft diameter.
Answer: Given, P = 3.75MW; N = 150 r.p.m.;
τ s = τ b = 50 MPa; n = 10, Db = 1.6 D
Shaft diameter, D :
2π NT
P=
60
2π × 150 × T
E 3.78 × 106 =
60
3.75 × 106 × 60
or T = = 238732 Nm
2π × 150
π
Also, T = τs × × D3
16
π
or 238732 = 50 × 106 × D3
16
⎛ 238732 × 16 ⎞
∴ D=⎜ ⎟ = 0.28 m or 290 mm
⎝ 50 × 10 × π ⎠
6

Bolt size,db :
Bolt pitch circle diameter, Db = 1.6 D = 1.6 × 0.29 = 0.464 m
π ⎛D ⎞
Now, T = n× db2 × τ b × ⎜ b ⎟
4 ⎝ 2 ⎠
π ⎛ 0.464 ⎞
or 238732 = 10 × db2 × 50 × 106 × ⎜ ⎟
4 ⎝ 2 ⎠
or db = 0.0512 m or 51.2 mm

Page 429 of 429